Purdue CMSC, in collaboration with Purdue Silicon Detector Laboratory (PSDL), is designing, prototyping, testing, and fabricating composite support structures for CERN’s Large Hadron Collider (LHC) CMS and ATLAS experiments. This is part of the particle collider’s High Luminosity upgrade, with installation of final components in 2026-27. The Thermwood LSAM 105 Additive Printer and five-axis LSAM Trim router at the Purdue LSAM Research Laboratory have enabled rapid large-scale printing and machining of trimming fixtures for the high precision composite tube structures. The 1m long, 208mm radius trimming fixture was printed on the LSAM with Acrylonitrile Butadiene Styrene (ABS) reinforced with 20% by weight of carbon fiber.

Machining Details

The faces that would become the trimming fixture base were machined to the flatness required for fixturing later. The printed, bonded fixture was then mounted on pedestals in the LSAM Additive Trimmer and the surface was machined to fit the nominal inner surface shape of the composites half-cylinders to be trimmed. Edge finding and reference features were machined into the trimming fixture to allow proper centering of the cured composite part.

Using this printed and machined fixture, the composite part edges were trimmed, interface holes drilled, mating surfaces machined flat and a scarf joint for joining the two half cylinders was created. The precision trimmed composite halves were then able to be bonded together.

Final Result

The final tube, 3.2m long, has to support 140kg of mass while only allowing sub millimeter deflections to occur. Purdue CMSC and PSDL will also be designing, fabricating, or testing other composite support structures for the CERN LHC upgrade as small as 0.5mm sheet goods and as large as 2.4m x 5m sandwich panel tubes. It is planned for the LSAM system to be utilized to create tooling and some final components for these other structures.

 

About CMSC

The Composites Manufacturing and Simulation Center (CMSC) of the College of Engineering and the Purdue Polytechnic are located in over 30,000 square feet of the Indiana Manufacturing Institute building. CMSC consists of faculty experts in composites manufacturing, a professional staff of doctoral degree engineers, a support staff and research students in doctoral, masters and bachelor’s degree programs of the Schools Aeronautics and Astronautics, Chemical Engineering and Materials Engineering, as well as, the Department of Aviation Technology in the Polytechnic.

A comprehensive set of laboratories is available at the IMI for the study of composites manufacturing processes, characterization of composite materials, and the validation of simulation software essential to development and verification of the digital twin concepts in composite manufacture and performance. Focus specialties include extrusion deposition additive manufacturing, composites autoclave processing of continuous fiber systems, compression and injection molding of discontinuous fiber composites, prepreg impregnation, infusion molding, sheet forming, complex mold-forming and hybrid continuous/discontinuous fiber systems. Workflow simulations are being developed to provide for end-to-end digital twins of these manufacturing processes. Accordingly, manufacturing informed performance predictions are a direct outcome of these workflow analyses.

About Thermwood Corporation

Thermwood is a US based, multinational, diversified CNC machinery manufacturer that markets its products and services through offices in 11 countries. Thermwood is the oldest manufacturer of highly flexible 3 & 5 axis high-speed machining centers known as CNC routers.

Thermwood has also become the technology and market leader in large scale additive manufacturing systems for thermoplastic composite molds, tooling, patterns and parts with its line of LSAM (Large Scale Additive Manufacturing) machines that both 3D print and trim on the same machine. These are some of the largest and most capable additive manufacturing systems ever produced and are marketed to major companies in the aerospace, marine, automotive and foundry industries as well as military, government and defense contractors.

 

Thermwood's AutoProcessor 43 Machining Center is an all-new complete, nested-based, CNC routing system for machining cabinet boxes, custom furniture and basically any nested type of sheet product.

Thermwood, who has been producing CNC routers for over 52 years has announced several promotions for long-time employees.  Please join us in congratulating these gentlemen and welcoming them to their new positions!  

Thermwood Promotes Jim Bullis to Vice President of Sales

We are pleased to announce the promotion of Jim Bullis to the Vice President of Sales position. In his new role, Jim will oversee the sales and operations of the Machining Products Division at Thermwood. 

Jim is a long-standing employee with over 26 years of experience at Thermwood. He has held numerous positions, initially starting as a Field Service Technician to Trade Show Manager and over the last 19 years as an Account Manager.

Jim resides in Southern Indiana with his wife, Jessy and children.

Thermwood Promotes Brendan Haas to Account Manager

We are pleased to announce the promotion of Brendan Haas to an Account Manager position within the Machining Products Division. In his new role, he will be responsible for sales and dealer relationships over his designated areas, which is approximately half of the US.

Brendan initially started at Thermwood as a Field Service Technician, and over the last three years, as an Upgrade Specialist in the Retrofit Department for Technical Services.

Brendan and his wife, Kateland reside in Holland, IN. 

Thermwood Promotes Pete Riddle to Upgrade Services Specialist

We are pleased to announce the promotion of Pete Riddle to Upgrade Service Specialist in the Retrofit Department. In his new role, Pete will be responsible for sales of upgrades, retrofits, refurbished machines and the Advanced Support Program.

Pete is a long-standing employee with approximately 21 years of experience at Thermwood. He has held numerous positions, initially as a Field Service Technician and then as Programming Support and for the last 11 years as Training Instructor.

Pete and his wife, Susan reside in southern Indiana.

About Thermwood Corporation

Thermwood is a US based, multinational, diversified CNC machinery manufacturer that markets its products and services through offices in 11 countries. Thermwood is the oldest manufacturer of highly flexible 3 & 5 axis high-speed machining centers known as CNC routers.

Thermwood has also become the technology and market leader in large scale additive manufacturing systems for thermoplastic composite molds, tooling, patterns and parts with its line of LSAM (Large Scale Additive Manufacturing) machines that both 3D print and trim on the same machine. These are some of the largest and most capable additive manufacturing systems ever produced and are marketed to major companies in the aerospace, marine, automotive and foundry industries as well as military, government and defense contractors.

Virtually all, if not all, large format, FDM additive systems, sold to industry in the last several years have been Thermwood LSAMs.

Watch the video below to learn 21 reasons why:

Thermwood routinely applies for patent protection on additive manufacturing technology it develops for its LSAM large format additive systems. During COVID, we received electronic copies of patents that were granted, however, the official hard copies were withheld.

A couple of days before Christmas 2021, we received a package containing the official hard copy of 32 additive manufacturing patents. This was certainly a one-day record for Thermwood and a welcome sight!

In addition to these latest patents, Thermwood already has a large portfolio of earlier issued patents covering the unique, large format (5x10 foot table and larger) 3D print technology it has developed. This LSAM technology is currently the most widely used large scale additive print technology operating in industry today. It’s used in a wide variety of industries including aerospace, transportation, heavy equipment, foundry and large decorative structures. It is being used to produce a diversity of products including aerospace patterns, molds and tooling, heavy equipment foundry patterns, bus chassis, large valve body foundry patterns and trim tooling. It was even used to print the tallest 3D printed structure in the world, the 92 foot tall Al Davis Memorial Torch at Allegiant stadium in Las Vegas.

Thermwood offers this unique patented technology on a wide variety of equipment, the largest, most diverse product offering of its kind available today. It includes a broad selection of machines, including single and dual gantry, fixed and moving table configurations, with both print-only and print-and-trim systems, from 5 by 10 foot to 20 by 60 foot print envelopes. We are working on even larger machines but that’s for another day.

The primary focus of the patented LSAM technology is to reliably and repeatedly produce the highest quality, best fused, most homogeneous printed structures possible from a variety of reinforced thermoplastic polymer composites including those intended to operate at elevated temperatures. Although it is nice to have been granted these patents, it is even nicer to finally have the official hard copies in hand.

Thermwood has added a third print orientation to its LSAM Large Scale Additive Manufacturing systems.

LSAM systems currently can print both horizontal and vertical layers if equipped with the Vertical Layer Print (VLP) option, available on most Thermwood LSAM machines. This new addition adds Angle Layer Printing (ALP) to the VLP option. Angle Layer Printing is the ability to print at a 45 degree angle.

LSAM Angle Layer Printing (ALP) shown

LSAM Regular Vertical Layer Printing (VLP) shown

LSAM Horizontal Layer Printing (HLP) shown

Maximum Print Flexibility

Each print orientation has advantages and limitations for a particular part design. Offering all three on the same machine, for the first time, means maximum print flexibility. All print orientations use the complete LSAM print head including exclusive LSAM print features such as the patented compression wheel and Thermal Sensor Layer Automation.

This helps maintain an even layer temperature throughout the print.  LSAM automatically adjusts the individual layer temperature to provide for superior layer fusion (as seen below).

LSAM machines are currently operating in regular daily industrial production with many existing systems already equipped with Vertical Layer Print capability. The Vertical Layer Print (VLP) option has been replaced with a VLP/ALP option on new machines which offers both vertical and angle layer print capability, in addition to the standard horizontal layer print.

Angle Layer Print (ALP) can be easily and inexpensively added to machines operating in the field that already have the VLP option.

If a machine was purchased without VLP, the entire new VLP/ALP Print option, can be added to most machines already in operation. It can be done in the field, but is a bit more involved.

Broad Line of LSAM Systems Available

Thermwood’s LSAM large scale additive systems are the most widely used large scale composite thermoplastic additive equipment in industrial production today. Virtually all, if not all, large scale additive systems installed in the last several years have been Thermwood LSAMs. Processing a variety of reinforced composite polymers from room temperature ABS and PC to high temperature material such as PSU, PESU and PEI, they are used to produce molds and tools for the aerospace industry, patterns for the foundry industry and for a variety of other unique applications.

LSAM systems are available in sizes from 5x10 foot to 15x60 foot in a variety of configurations including print only and full print and trim, making it the broadest product offering in the large scale additive arena. Print heads are available that can print thermoplastic composite material at rates from 200 pounds per hour to over 500 pounds per hour.

They have a variety of exclusive features including a temperature controlled compression wheel and automatic thermal layer speed control, both of which help assure the best possible fusion between printed layers.

With the addition of Angle Layer Print, these systems have become even more capable and more flexible.

Finished LSAM Angle Layer Print (rear view)

Finished LSAM Angle Layer Print (front view)

Live Printing

Thermwood will be printing high temp autoclave aerospace tooling on an LSAM Additive Printer 510 LIVE at CAMX 2021 in Dallas, TX, October 19th-21st in Booth #M44B.  LSAM Research Laboratory at Purdue ADDITIVE3D simulation software will be on display as well in adjacent Booth #M44, with Purdue representatives on site for demonstrations.  We will be printing a different material each day, donated by AIRTECH, SABIC AND TECHMER PM.  This promises to be an exciting demonstration of the LSAM Additive Printer Large Scale Additive System! 

Free CAMX 2021 Exhibit Pass & 15% off Conference Registration Fee

Click the link below to Be Our Guest and register for a Free CAMX Exhibit pass and 15% off the Conference Registration Fee.

Free Exhibit Hall Pass Code: FREEEX021

15% off Full Conference Registration Code: FREEFULL21

Make plans now to visit the Kay Bailey Hutchinson Convention Center and stop by Thermwood Booth #M44B to witness this live and in-person!

LSAM Research Laboratory at Purdue ADDITIVE3D Software on Display

Representatives from the recently announced Thermwood Research Laboratory at Purdue University (located in Purdue University's Composites Manufacturing Simulation Center - CSMC) will also be on hand to demonstrate their ADDITVE3D simulation software.

AIRTECH High Temp Material - Tuesday, October 19th

On Tuesday, October 19th, we will be printing AIRTECH PEI DALTRAM I-350CF

SABIC High Temp Material - Wednesday, October 20th

On Wednesday, October 20th we will be printing SABIC LNP™ THERMOCOMP™ AM EC004XXAR1 ULTEM compound.

TECHMER PM High Temp Material - Thursday, October 21st

On Thursday, October 21st, we will be printing TECHMERPM PESU 1810 3DP.

Dale, Indiana based Thermwood Corporation will enter into an LSAM/Thermwood sponsorship arrangement with Columbus, Ohio based Alliance Autosport for one of Thermwood’s own employees. The employee will be racing in the Sports Car Club of America (SCCA) “Runoffs” at the famed Indianapolis Motor Speedway during the last week of September and into October.

The Runoffs is the SCCA’s annual winner-take-all national championship. The competition brings together the best qualified amateur racers from all over the US and Canada to compete across 26 different race car classes for the 58th consecutive year.

The young driver, Gabe Fehribach, is a member of Thermwood’s engineering team. Gabe fulfilled his Runoffs qualification requirements earlier this year after racing at such storied venues as VIRginia International Raceway, Circuit of the Americas, Mid-Ohio Sports Car Course, and Watkins Glen International, among others.

Following three days of qualifying beginning September 28th, Gabe will compete with his winged, open-wheel SCCA Enterprises Formula Enterprises 2 race car the morning of Friday, October 1st against 28 other drivers all running the same spec chassis, Sunoco fuel, Hoosier tires, and Mazda power unit.

Tickets for the three days of racing beginning October 1st can be purchased through the Indianapolis Motor Speedway website.

For more information on Thermwood, the SCCA Runoffs, Alliance Autosport, and Indianapolis Motor Speedway, visit these websites:

http://www.thermwood.com
http://www.scca.com/runoffs
http://www.allianceautosport.com
http://www.indianapolismotorspeedway.com

Live Printing

Thermwood will be printing high temp autoclave aerospace tooling on an LSAM Additive Printer 510 LIVE at RAPID + TCT 2021 in Chicago, IL September 13th-15th.  LSAM Research Laboratory at Purdue ADDITIVE3D Software will be on display as well, with Purdue representatives on site for demonstrations.  We will be printing a different material each day, donated by SABIC, TECHMER PM and AIRTECH.  This promises to be an exciting demonstration of the LSAM Additive Printer Large Scale Additive System. 

Free Rapid + TCT Expo Pass & $100 off Conference Registration Fee

Click the link below to Be Our Guest and register for a Free Rapid + TCT Expo pass and $100 off the Conference Registration Fee.

Use Promo Code: 10016220

Make plans now to visit the McCormick Center and stop by Thermwood booth #E7628 to witness this live and in-person!

LSAM Research Laboratory at Purdue ADDITIVE3D Software on Display

Representatives from the recently announced Thermwood Research Laboratory at Purdue University (located in Purdue University's Composites Manufacturing Simulation Center - CSMC) will also be on hand to demonstrate their ADDITVE3D simulation software.

SABIC High Temp Material - September 13th

On Monday, September 13th we will be printing SABIC LNP™ THERMOCOMP™ AM EC004XXAR1 ULTEM compound.

TECHMER PM High Temp Material - Tuesday, September 14th

On Tuesday, September 14th, we will be printing TECHMERPM PESU 1810 3DP.

AIRTECH High Temp Material - Wednesday, September 15th

On Wednesday, September 15th, we will be printing AIRTECH PEI DALTRAM I-350CF

A Manager's Guide to Large Scale Additive Manufacturing

This 315 page book, currently available as either an eBook or paperback hardcopy, is intended to help non-technical managers understand the basics behind a new technology that is revolutionizing production of large composite molds, tools and other industrial and commercial products.

Where to Purchase

This book is currently available from Amazon either as an electronic file or as a printed hardcopy.

Who This Book is For

If you are a manager in an industrial company who might benefit from large scale additive technology, or, if your company is actively exploring this technology, this book will give you the background you need to participate and make better decisions. It will also help you cut through the confusion and crosstalk that often accompanies a new technology like this.